U.S. patent application number 16/939431 was filed with the patent office on 2022-01-27 for appliance liner having natural fibers.
This patent application is currently assigned to WHIRLPOOL CORPORATION. The applicant listed for this patent is WHIRLPOOL CORPORATION. Invention is credited to Muhammad Khizar.
Application Number | 20220024192 16/939431 |
Document ID | / |
Family ID | 1000005032027 |
Filed Date | 2022-01-27 |
United States Patent
Application |
20220024192 |
Kind Code |
A1 |
Khizar; Muhammad |
January 27, 2022 |
APPLIANCE LINER HAVING NATURAL FIBERS
Abstract
A household appliance liner includes a first polymeric capping
layer and a polymeric base layer. The first polymeric capping layer
includes a first pigment additive. The polymeric base layer is
coupled to the first polymeric capping layer. The polymeric base
layer includes one or more polymers, a second pigment additive, and
a natural fiber. The natural fiber can be present at a
concentration of at least 50% by weight of the polymeric base
layer. Methods of producing the household appliance liner are also
disclosed.
Inventors: |
Khizar; Muhammad; (St.
Joseph, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
WHIRLPOOL CORPORATION |
BENTON HARBOR |
MI |
US |
|
|
Assignee: |
WHIRLPOOL CORPORATION
BENTON HARBOR
MI
|
Family ID: |
1000005032027 |
Appl. No.: |
16/939431 |
Filed: |
July 27, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29K 2311/00 20130101;
B32B 2270/00 20130101; B32B 27/302 20130101; B32B 27/08 20130101;
B29C 48/022 20190201; B29K 2105/0032 20130101; B32B 27/32 20130101;
B32B 27/20 20130101; B29K 2023/06 20130101; B32B 27/308 20130101;
B32B 2509/10 20130101 |
International
Class: |
B32B 27/20 20060101
B32B027/20; B32B 27/08 20060101 B32B027/08; B32B 27/30 20060101
B32B027/30; B32B 27/32 20060101 B32B027/32 |
Claims
1. A household appliance liner, comprising: a first polymeric
capping layer comprising a first pigment additive; and a polymeric
base layer coupled to the first polymeric capping layer, the
polymeric base layer comprising: one or more polymers; a second
pigment additive; and a natural fiber, the natural fiber being
present at a concentration of at least 50% by weight of the
polymeric base layer.
2. The household appliance liner of claim 1, further comprising: a
second polymeric capping layer coupled to the first polymeric
capping layer such that the first polymeric capping layer is
positioned between the polymeric base layer and the second
polymeric capping layer.
3. The household appliance liner of claim 2, wherein the second
polymeric capping layer is a scratch-resistant layer.
4. The household appliance liner of claim 3, wherein the second
polymeric capping layer comprises poly(methyl methacrylate).
5. The household appliance liner of claim 1, wherein the first
pigment additive in the first polymeric capping layer is present at
a concentration of about 5% to about 30% by weight of the first
polymeric capping layer.
6. The household appliance liner of claim 5, wherein the first
polymeric capping layer comprises a first polymeric capping layer
precursor at a concentration of about 70% to about 95% by weight of
the first polymeric capping layer.
7. The household appliance liner of claim 1, wherein the second
pigment additive is present in the polymeric base layer at a
concentration of about 1% to about 30% by weight of the polymeric
base layer.
8. The household appliance liner of claim 7, wherein the one or
more polymers of the polymeric base layer comprises a colored
polyethylene blend and a high-impact polystyrene.
9. The household appliance liner of claim 8, wherein the colored
polyethylene blend comprises the second pigment additive at a
concentration of about 4% by weight of the colored polyethylene
blend, and wherein the colored polyethylene blend comprises
polyethylene at a concentration of about 96% by weight of the
colored polyethylene blend.
10. The household appliance liner of claim 8, wherein the colored
polyethylene blend is present at a concentration of about 30% by
weight of the one or more polymers and the high-impact polystyrene
is present at a concentration of about 70% by weight of the one or
more polymers.
11. The household appliance liner of claim 7, wherein the
concentration of the second pigment additive in the polymeric base
layer is about equal within the one or more polymers and the
natural fiber.
12. The household appliance liner of claim 11, wherein the natural
fiber is bleached and pre-colored with the second pigment additive
prior to mixing the natural fiber with the one or more
polymers.
13. The household appliance liner of claim 11, wherein the second
pigment additive is added to the one or more polymers and the
natural fiber in equal amounts prior to mixing the one or more
polymers and the natural fiber.
14. The household appliance liner of claim 1, further comprising: a
barrier layer coupled to the polymeric base layer such that the
barrier layer is positioned between the first polymeric capping
layer and the polymeric base layer.
15. A household appliance liner, comprising: a first polymeric
capping layer comprising: a first pigment additive, wherein the
first pigment additive is present at a concentration of about 5% to
about 30% by weight of the first polymeric capping layer; and a
first polymeric capping layer precursor at a concentration of about
70% to about 95% by weight of the first polymeric capping layer;
and a polymeric base layer coupled to the first polymeric capping
layer, the polymeric base layer comprising: one or more polymers; a
second pigment additive, wherein the second pigment additive is
present in the polymeric base layer at a concentration of about 1%
to about 30% by weight of the polymeric base layer; and a natural
fiber, the natural fiber being present at a concentration of at
least 50% by weight of the polymeric base layer.
16. The household appliance liner of claim 15, wherein the one or
more polymers of the polymeric base layer comprises a colored
polyethylene blend and a high-impact polystyrene, wherein the
colored polyethylene blend comprises the second pigment additive at
a concentration of about 4% by weight of the colored polyethylene
blend, and wherein the colored polyethylene blend comprises
polyethylene at a concentration of about 96% by weight of the
colored polyethylene blend.
17. The household appliance liner of claim 16, wherein the colored
polyethylene blend is present at a concentration of about 30% by
weight of the one or more polymers and the high-impact polystyrene
is present at a concentration of about 70% by weight of the one or
more polymers.
18. A method of making a liner for a household appliance, the
method comprising: mixing a first polymeric capping layer precursor
and a first pigment additive to form a first polymeric capping
layer, wherein the first pigment additive is present at a
concentration of about 5% to about 30% by weight of the first
polymeric capping layer; mixing one or more polymers, a second
pigment additive, and a natural fiber to form a polymeric base
resin; extruding the polymeric base resin to form a polymeric base
layer at a base layer formation temperature, wherein the second
pigment additive is present in the polymeric base layer at a
concentration of about 1% to about 30% by weight of the polymeric
base layer, and wherein the natural fiber is present at a
concentration of at least 50% by weight of the polymeric base
layer; and laminating the polymeric base layer and the first
polymeric capping layer to form the liner at about the base layer
formation temperature.
19. The method of making a liner for a household appliance of claim
18, wherein the step of mixing one or more polymers, a second
pigment additive, and a natural fiber to form a polymeric base
resin further comprises: mixing the second pigment additive with
the one or more polymers and the natural fiber in equal amounts
prior to mixing the one or more polymers and the natural fiber
together.
20. The method of making a liner for a household appliance of claim
18, wherein the step of mixing one or more polymers, a second
pigment additive, and a natural fiber to form a polymeric base
resin further comprises: bleaching the natural fiber; and
pre-coloring the natural fiber with the second pigment additive,
with the bleaching and pre-coloring of the natural fiber occurring
prior to mixing the natural fiber with the one or more polymers.
Description
FIELD OF THE DISCLOSURE
[0001] The present disclosure generally relates to liners for
appliances. More specifically, the present disclosure generally
relates to appliance liners having natural fibers.
BACKGROUND
[0002] This application relates to liners having particular colors,
hues, tints, and the like which are desired for many
appliance-related applications, such as refrigeration appliances.
As appliance designers have recently placed more emphasis on
interior design and lighting (e.g., given the lower energy usage of
light-emitting diode (LED) sources), the importance of interior
aesthetics has increased for many consumers. Similarly, appliance
manufacturers often emphasize aesthetics, including interior design
approaches, in attempting to obtain brand differentiation from
their competitors.
[0003] Liners employed in appliances, including refrigeration
appliances, are often produced with extrusion processes. As these
liners often are fabricated from two or more layers, conventional
approaches to adding color to these liners often involve adding
pigments to each extruder employed in making a layer employed in
the liner. As pigments are added to multiple extruders, the
complexity, repeatability, and manufacturing cost of matching
colors increases significantly for a liner that comprises two or
more layers having pigments. Further, as significant loadings of
pigments in these multi-layer liners are often employed,
down-stream processes such as thermal forming used to incorporate
the liners into an end product can lead to local discoloration and
yield losses. Further, multiple and cost-intensive extrusion runs
are often required to fabricate a liner having multiple, extruded
layers with pigments that match a particular color, tint, or hue.
Still further, these approaches for making a liner having multiple,
extruded pigmented layers require one or more adhesives to bond the
layers, which increases the cost and can decrease manufacturing
yield.
[0004] Colored liners currently being utilized in appliances
frequently present problems during manufacturing since these liners
readily show scratches or defects in the liner surface where the
pigment is incorporated. Such scratches imparted on the liner
during either the manufacturing process or use by consumers can
lead to premature wearing where the inside surface of the
refrigeration appliance can look excessively worn or damaged. The
flexibility and ability to produce liners where scratches are not
readily shown would be beneficial to both manufactures and users
for both the production process and downstream aesthetic
appearances.
[0005] Accordingly, there is a need for methods of making liners,
particularly pigmented liners for refrigeration appliances, which
are repeatable, with high manufacturing flexibility, and low in
cost. There is also a need for pigmented liners that do not readily
show scratches or other wear marks that may be transferred to the
liner surface during fabrication or consumer use.
SUMMARY OF THE DISCLOSURE
[0006] In at least one aspect of the present disclosure, a
household appliance liner is provided. The household appliance
liner includes a first polymeric capping layer and a polymeric base
layer. The first polymeric capping layer includes a first pigment
additive. The polymeric base layer is coupled to the first
polymeric capping layer. The polymeric base layer includes one or
more polymers, a second pigment additive, and a natural fiber. The
natural fiber is present at a concentration of at least 50% by
weight of the polymeric base layer.
[0007] According to another aspect of the present disclosure, a
household appliance liner is provided. The household appliance
liner includes a first polymeric capping layer and a polymeric base
layer. The polymeric base layer is coupled to the first polymeric
capping layer. The first polymeric capping layer includes a first
pigment additive and a first polymeric capping layer precursor. The
first pigment additive is present at a concentration of about 5% to
about 30% by weight of the first polymeric capping layer. The first
polymeric capping layer precursor is present at a concentration of
about 70% to about 95% by weight of the first polymeric capping
layer. The polymeric base layer includes one or more polymers, a
second pigment additive, and a natural fiber. The second pigment
additive is present in the polymeric base layer at a concentration
of about 1% to about 30% by weight of the polymeric base layer. The
natural fiber is present at a concentration of at least 50% by
weight of the polymeric base layer.
[0008] According to yet another aspect of the present disclosure, a
method of making a liner for a household appliance is provided. The
method includes the step of mixing a first polymeric capping layer
precursor and a first pigment additive to form a first polymeric
capping layer. The first pigment additive is present at a
concentration of about 5% to about 30% by weight of the first
polymeric capping layer. The method also includes the step of
mixing one or more polymers, a second pigment additive, and a
natural fiber to form a polymeric base resin. The method further
includes the step of extruding the polymeric base resin to form a
polymeric base layer at a base layer formation temperature. The
second pigment additive is present in the polymeric base layer at a
concentration of about 1% to about 30% by weight of the polymeric
base layer. The natural fiber is present at a concentration of at
least 50% by weight of the polymeric base layer. The method also
includes the step of laminating the polymeric base layer and the
first polymeric capping layer to form the liner at about the base
layer formation temperature.
[0009] These and other features, advantages, and objects of the
present device will be further understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing summary, as well as the following detailed
description of the device, will be better understood when read in
conjunction with the appended drawings. For the purpose of
illustrating the device, there are shown in the drawings, certain
embodiment(s) that are presently preferred. It should be
understood, however, that the device is not limited to the precise
arrangements and instrumentalities shown. Drawings are not
necessary to scale. Certain features of the device may be
exaggerated in scale or shown in schematic form in the interest of
clarity and conciseness.
[0011] In the drawings:
[0012] FIG. 1 is a schematic of a refrigeration appliance including
a liner according to aspects of the present disclosure;
[0013] FIG. 2A is a schematic of an enlarged cross-section of the
liner at region II marked in FIG. 1 including a first polymeric
capping layer, a barrier layer, and a polymeric base layer,
according to some aspects of the present disclosure;
[0014] FIG. 2B is a schematic of an enlarged cross-section of the
liner at region II marked in FIG. 1 including the first polymeric
capping layer and the polymeric base layer according to some
aspects of the present disclosure;
[0015] FIG. 2C is a schematic view of an enlarged cross-section of
the liner at region II marked in FIG. 1 including the first
polymeric capping layer and the polymeric base layer according to
some aspects of the present disclosure;
[0016] FIG. 2D is a schematic view of an enlarged cross-section of
the liner at region II marked in FIG. 1 including the first
polymeric capping layer, the polymeric base layer, and a second
polymeric capping layer according to some aspects of the present
disclosure;
[0017] FIG. 3A is a flow-chart schematic of a method for making a
liner for an appliance according to some aspects of the present
disclosure;
[0018] FIG. 3B is an illustrated schematic of the method for making
a liner for an appliance according to some aspects of the present
disclosure;
[0019] FIG. 4A is a schematic of a hot lamination process according
to some aspects of the present disclosure;
[0020] FIG. 4B is a schematic of a hot lamination process according
to other aspects of the present disclosure; and
[0021] FIG. 5 is a schematic for shaping the liner into a final
liner to be installed in the refrigeration appliance according to
some aspects of the present disclosure.
DETAILED DESCRIPTION
[0022] Before the subject device is described further, it is to be
understood that the device is not limited to the particular
embodiments of the device described below, as variations of the
particular embodiments may be made and still fall within the scope
of the appended claims. It is also to be understood that the
terminology employed is for the purpose of describing particular
embodiments or aspects of embodiments, and is not intended to be
limiting. Instead, the scope of the present device will be
established by the appended claims.
[0023] Where a range of values is provided, it is understood that
each intervening value, to the tenth of the unit of the lower limit
unless the context clearly dictates otherwise, between the upper
and lower limit of that range, and any other stated or intervening
value in that stated range, is encompassed within the device. The
upper and lower limits of these smaller ranges may independently be
included in the smaller ranges, and are also encompassed within the
device, subject to any specifically excluded limit in the stated
range. Where the stated range includes one or both of the limits,
ranges excluding either or both of those included limits are also
included in the device.
[0024] In this specification and the appended claims, the singular
forms "a," "an" and "the" include plural reference unless the
context clearly dictates otherwise.
[0025] Referring to FIGS. 1-5, a liner 10 for a household appliance
14 and methods of making the same are disclosed. The liner 10 for
the household appliance 14 includes a first polymeric capping layer
18 and a polymeric base layer 22. The first polymeric capping layer
18 includes a first pigment additive 26. The polymeric base layer
22 is coupled to the first polymeric capping layer 18. The
polymeric base layer 22 includes one or more polymers 30, a second
pigment additive 34, and a natural fiber 38. The natural fiber 38
may be present at a concentration of at least 50% by weight of the
polymeric base layer 22. In various aspects, the liner 10 may
include a barrier layer 42. In some aspects, a second polymeric
capping layer 46 may be coupled to the first polymeric capping
layer 18 such that the first polymeric capping layer 18 is
positioned between the polymeric base layer 22 and the second
polymeric capping layer 46.
[0026] Referring again to FIGS. 1-5, a method 200 of making the
liner 10 for the household appliance 14 can include mixing a first
polymeric capping layer precursor 50 and the first pigment additive
26 to form the first polymeric capping layer 18 (step 204). The
first pigment additive 26 may be present at a concentration of
about 5% to about 30% by weight of the first polymeric capping
layer 18. The method 200 can include mixing the one or more
polymers 30, the second pigment additive 34, and the natural fiber
38 to form a polymeric base resin 54. In various aspects, the first
pigment additive 26 and the second pigment additive 34 may be
identical. While the first pigment additive 26 and the second
pigment additive 34 may be identical, the present disclosure may
maintain the separate terminology of the pigment additive(s) in an
effort to enhance clarity and aid in distinguishing a location of
the given pigment additive (e.g., first polymeric capping layer 18
or polymeric base layer 22). The method 200 can include extruding
the polymeric base resin 54 to form the polymeric base layer 22 at
a base layer formation temperature (step 208). The second pigment
additive 34 may be present in the polymeric base layer 22 at a
concentration of about 1% to about 30% by weight of the polymeric
base layer 22. The natural fiber 38 may be present at a
concentration of at least 50% by weight of the polymeric base layer
22. The method 200 can include laminating the polymeric base layer
22 and the first polymeric capping layer 18 to form the liner 10 at
about the base layer formation temperature (step 212). In various
aspects, the method 200 may further include laminating the barrier
layer 42 between the polymeric base layer 22 and the first
polymeric capping layer 18 to form the liner 10 at about the base
layer formation temperature. In some aspects, the method 200 may
include extruding the second polymeric capping layer 46. In various
aspects, the method 200 may include forming a textured pattern 58
on an outer surface 62 of the first polymeric capping layer 18
(step 216). The formed liner 10 includes a first capping region 66,
an optional barrier region 70, and a base region 74. The first
capping region 66 includes the first pigment additive 26. The base
region 74 includes the first pigment additive 26 and/or the second
pigment additive 34. In various aspects, the method 200 may include
shaping the liner 10 into a final liner 78 at a shaping temperature
where the final liner 78 is configured and/or is suitable for
assembly into a refrigeration appliance (step 220).
[0027] Referring now to FIG. 1, the household appliance 14 is
provided in an exemplary form that includes the liner 10 according
to some aspects. As shown, the liner 10 is mounted to a cabinet 82
of the household appliance 14. In some configurations, the liner 10
is mounted to a foam layer 86 (see FIGS. 2A-2D) installed on an
interior surface of the cabinet 82. In other configurations, the
liner 10 may be mounted directly to the cabinet 82. Typically, the
liner 10 is attached, coupled, joined, or otherwise fastened to the
cabinet 82 through the insulating foam 86, adhesive, bonding agent,
mechanical fastener (e.g., rivets, screws, etc.), or another
comparable approach. However, the liner 10 itself does not include
any internal adhesives and, according to some aspects, includes one
or more pigment additives (e.g., the first pigment additive 26) in
the first polymeric capping layer 18 only (see FIGS. 2A-2B).
[0028] Referring to FIGS. 2A-2D, the liner 10 of the household
appliance 14 includes the first polymeric capping layer 18 and the
polymeric base layer 22. The first polymeric capping layer 18
includes the first pigment additive 26. The first pigment additive
26 may be present in the first polymeric capping layer 18 at a
concentration of about 5% to about 30% by weight of the first
polymeric capping layer 18. The first polymeric capping layer 18
can also include the first polymeric capping layer precursor 50,
which will be discussed in further detail herein. The first
polymeric capping layer precursor 50 can be present in the first
polymeric capping layer 18 at a balancing concentration relative to
the first pigment additive 26. For example, the first polymeric
capping layer precursor 50 can be present in the first polymeric
capping layer 18 at a concentration of about 70% to about 95% by
weight of the first polymeric capping layer 18. The polymeric base
layer 22 includes the one or more polymers 30, the second pigment
additive 34, and the natural fiber 38. The one or more polymers 30
can be present in the polymeric base layer 22 at a concentration of
50% or less by weight of the polymeric base layer 22. For example,
the one or more polymers 30 may be present in the polymeric base
layer 22 at a concentration of 50% by weight, less than 50% by
weight, about 45% by weight, about 40% by weight, about 35% by
weight, about 30% by weight, about 25% by weight, about 20% by
weight, about 15% by weight, about 10% by weight, about 5% by
weight, greater than zero percent by weight, and/or combinations or
ranges thereof. Discussion of the concentration of the one or more
polymers 30 within the polymeric base layer 22 are intended to
refer to a total or combined concentration of the one or more
polymers 30 as opposed to individual concentrations of the one or
more polymers 30. For example, a concentration of the one or more
polymers 30 that is about 40% by weight of the polymeric base layer
22 may include about 20% by weight of Polymer A and about 20% by
weight of Polymer B. The second pigment additive 34 can be present
in the polymeric base layer 22 at a concentration of about 1% to
about 30% by weight of the polymeric base layer 22. For example,
the second pigment additive 34 can be present in the polymeric base
layer 22 at a concentration of about 1% by weight, about 5% by
weight, about 10% by weight, about 15% by weight, about 20% by
weight, about 25% by weight, about 30% by weight, and/or
combinations or ranges thereof. The natural fiber 38 can be present
in the polymeric base layer 22 at a concentration of between 15% by
weight of the polymeric base layer 22 and 65% by weight of the
polymeric base layer 22. In various examples, the natural fiber 38
can be present in the polymeric base layer 22 at a concentration of
about 15% by weight, about 20% by weight, about 30% by weight,
about 35% by weight, about 40% by weight, about 45% by weight,
about 50% by weight, about 55% by weight, about 60% by weight,
about 65% by weight, and/or combinations or ranges thereof. In some
examples, the liner 10 of the household appliance 14 may be
provided with the barrier layer 42 and/or the second polymeric
capping layer 46, as will be discussed in further detail herein.
The various examples of the liner 10 disclosed herein are exemplary
in nature. Accordingly, the characteristics of a given layer of the
liner 10 discussed with regard to one example may be applicable in
whole or in part to additional and/or alternative examples.
[0029] Referring now to FIG. 2A, the liner 10 (e.g., as
incorporated into the household appliance 14 depicted in FIG. 1)
includes the first polymeric capping layer 18 and corresponding
first capping region 66, the polymeric base layer 22 and
corresponding base region 74, and the barrier layer 42 and
corresponding barrier region 70. The liner 10 and its combination
of the barrier layer 42 sandwiched between the first polymeric
capping layer 18 and polymeric base layer 22 may be positioned
directly onto the foam layer 86. In some aspects, the foam layer 86
may include closed-cell and/or open-cell voids, air bubbles, and/or
pores 90 distributed evenly throughout the foam layer 86. In some
aspects, the foam layer 86 imparts an insulation layer between the
liner 10 and the wrapper and/or cabinet 82 of the household
appliance 14. The first polymeric capping layer precursor 50 used
to form the first polymeric capping layer 18 may include a
high-impact polystyrene (HIPS), poly(methyl methacrylate) (PMMA),
polystyrene (PS), acrylonitrile butadiene styrene (ABS),
polyurethane (PU), polypropylene (PP), polyethylene (PE), or
combinations thereof. In some aspects, the first polymeric capping
layer precursor 50 selected for use in the first polymeric capping
layer 18 may be any known thermoplastic known in the art suitable
for use in an extrusion process. In other aspects, the first
polymeric capping layer precursor used to form the first polymeric
capping layer 18 may include a high-impact polystyrene precursor
material (e.g., 1115 HIPS). As also depicted in FIG. 2A, the first
polymeric capping layer 18 can be configured to have a thickness 94
(e.g., through extrusion, rolling, etc.) of about 0.10 mm to about
1.5 mm. In some aspects, the thickness 94 of the first polymeric
capping layer 18 may range from about 0.25 mm to about 0.75 mm.
Note that the thickness 94 of the first polymeric capping layer 18
is given in approximate dimensions, as would be typically
associated with the first polymeric capping layer 18 being in a
sheet or layer form before incorporation into the liner 10. The
first pigment additive 26 may be incorporated and/or disbursed
within the first polymeric capping layer 18 at a level sufficient
to impart a desired color, hue, tinting, or the like in the liner
10.
[0030] Referring again to FIG. 2A, the textured pattern 58 may be
positioned on the outer surface 62 of the first polymeric capping
layer 18 of the liner 10. The textured or granular pattern 58 is
beneficial for the color and aesthetic preservation of the liner 10
over time since the textured pattern 58 can help protect the first
polymeric capping layer 18 from visibly showing scratches, rub
marks, gouges, and/or scrapes. Additionally, when the textured
pattern 58 is employed on the outer surface 62 of the first
polymeric capping layer 18, the first pigment additive 26 may be
spaced away from the outer surface 62 of the liner 10. The textured
pattern 58 can provided wear resistance and prevent contact between
the first pigment additive 26 and the user and/or potential food
products stored in the household appliance 14. The textured pattern
58 may include a variety of different surface patterns formed on
the first polymeric capping layer 18, for example, pyramidal,
diamond, circular, trapezoidal, square, tetragonal, hexagonal,
polygonal, or a combination of shapes thereof. In some aspects, the
textured pattern 58 may include a 2D surface pattern, a 3D surface
pattern, or a combination thereof. The textured or granular pattern
58 helps prevent visible markings or wear of the outer surface 62
of the liner 10 by offering an alternative to a glossy or smooth
finished surface that can readily show marks or wear from the
manufacturing process or normal wear. In some aspects, the textured
or granular pattern 58 can absorb a scratch, scuff, and/or gouge
while the textured pattern 58 can blend in or camouflage the
respective mark. In some examples, the textured pattern 58 may be
omitted such that the outer surface 62 is provided with a smooth
appearance.
[0031] Referring further to FIG. 2A, the first polymeric capping
layer 18 of the liner 10 may include one or more pigment additives
(e.g., first pigment additive 26), configured to impart color,
tinting, or the like into the liner 10. As understood by those with
ordinary skill in the field of the disclosure, various metallic,
ceramic, and/or polymeric, pigments and/or colorants can be added
at various concentrations within the first polymeric capping layer
precursor 50 employed in the first polymeric capping layer 18 of
the liner 10. In some aspects, the first pigment additive 26 is a
granulated pigment. For example, titanium oxide can be included as
the first pigment additive 26 to achieve a white color. In other
aspects, the liner 10 having a charcoal-sparkle appearance can be
created by employing carbon black in one or more of quartz, mica,
and stainless steel as the first pigment additive 26. In some
aspects of the disclosure, the first pigment additives 26 are
incorporated into the first capping region 66 of the first
polymeric capping layer 18 at a concentration level and disbursed
to ensure that the liner 10 exhibits a particular color, hue, or
the like, as desired by the user of the household appliance 14. In
some aspects, no additional pigment additives are used, directly or
indirectly transferred, and/or incorporated in the base region 74
of the polymeric base layer 22 to obtain the desired color, hue, or
tinting for the liner 10. According to other aspects, the first
pigment additive 26 may be incorporated into the first capping
region 66 and the base region 74 at concentrations sufficient for
the liner 10 to obtain the desired color, hue, or tinting. In such
aspects, the second pigment additive 34 may be identical to the
first pigment additive 26. In some aspects, the mixing step 204
includes mixing the first polymeric capping layer precursor 50 with
about 5% to about 30% first pigment additive 26 by weight of the
first polymeric capping layer 18. According to some aspects, the
first pigment additives 26 are incorporated into the first capping
region 66 of the first polymeric capping layer 18 at a
concentration from about 10% to about 25% (by weight of the first
polymeric capping layer 18). Optionally, the first pigment
additives 26 may be incorporated into the first capping region 66
at a concentration from about 1% to about 10% (by weight of the
first polymeric capping layer 18). In still other aspects, the
concentration of the first pigment additive 26 in the first capping
region 66 of the first polymeric capping layer 18 is loaded between
about 15% to about 25% (by weight of the first polymeric capping
layer 18) and in the base region 74 of the polymeric base layer 22,
if present, from about 3% to about 5% (by weight of the base layer
22). In some aspects, the first polymeric capping layer comprises
from about 70% to about 95% by weight first polymeric capping layer
precursor 50 and from about 5% to about 30% first pigment additive
26 by weight.
[0032] Referring still further to FIG. 2A, the barrier layer 42 and
corresponding barrier region 70 may help protect the liner 10 from
wrinkling, deformations, and/or delamination effects caused during
manufacturing or end use. In some aspects, the barrier layer 42 may
prevent the diffusion of volatiles and other potential contaminants
associated with injecting the foam 86 positioned between the liner
10 and the cabinet 82. In some aspects, the contaminants associated
with the foam 86 that could discolor or lead to other deteriorating
defects in the liner 10 have no negative effects on the first
polymeric capping layer 18 disclosed herein. The barrier layer 42
may be sandwiched directly between the first polymeric capping
layer 18 and polymeric base layer 22 to form the liner 10 with no
additional adhesives and/or bonding agents used between the
respective layers 18, 22, 42. In some aspects, the barrier region
70 includes a polyethylene material used in combination with a
material employed in the base region 74, typically a material
comparable to that employed in the first polymeric capping layer 18
or first capping region 66, e.g., a high-impact polystyrene (HIPS).
In some aspects, the barrier layer 42 may be formed using a low
density polyethylene, a high density polyethylene, a polypropylene,
a polycarbonate, a polyester, a polyamide, a polystyrene, a
high-impact polystyrene (HIPS), or a combination thereof. According
to some aspects, additional compatibilizers, as understood by those
with ordinary skill in the art, are added to the barrier region 70
to ensure that the polyethylene layers and HIPS material within the
barrier region 70 are combined without the formation of voids,
bubbles, delamination defects, etc. In some aspects, the barrier
region 70 may include one or more barrier layers 42 comprising a
polyethylene material, layered on the respective material of the
base layer 22. As also depicted in FIG. 2A, the barrier region 70
of the barrier layer 42 can be configured with a thickness 98
(e.g., through extrusion, rolling, etc.) of about 0.10 mm to about
1.5 mm. In some aspects, the barrier layer 42 has a thickness 98 of
about 0.25 mm to about 0.75 mm. Note that the thickness 98 of the
barrier layer 42 is given in approximate dimensions, as would be
typically associated with the barrier layer 42 being in a sheet or
layer form before incorporation into the liner 10.
[0033] Referring again to FIG. 2A, the polymeric base layer 22 may
provide structural support to the liner 10. The polymeric base
resin 54 used to form the base region 74 of the polymeric base
layer 22 may include a high-impact polystyrene (HIPS), poly(methyl
methacrylate) (PMMA), polystyrene (PS), acrylonitrile butadiene
styrene (ABS), polyurethane (PU), polypropylene (PP), polyethylene
(PE), or combinations thereof. In some aspects, the polymeric base
resin 54 selected for use in the base layer 22 are thermoplastics,
suitable for use in an extrusion process. In other aspects, the
polymeric base resin 54 (see FIGS. 4A and 4B) used to form the
polymeric base layer 22 may include a high-impact polystyrene (1170
HIPS) precursor material. As also depicted in FIG. 2A, the base
region 74 of the polymeric base layer 22 can be configured with a
thickness 102 (e.g., through extrusion, rolling, etc.) of about
0.10 mm to about 1.5 mm. In some aspects, the polymeric base layer
22 has thickness 102 of about 0.25 mm to about 0.75 mm. Note that
the thickness 102 of the base layer 22 is given in approximate
dimensions, as would be typically associated with the polymeric
base layer 22 being in a sheet or layer form before incorporation
into the liner 10.
[0034] Referring further to FIG. 2A, the liner 10 is configured
such that the first capping region 66, the barrier region 70, and
the base region 74 (i.e., for liner 10) are joined with
substantially no interfaces between them. The term "interface", as
defined herein, is meant to include boundaries marked by structural
defects such as cracks, folds, or bubbles where two layers (e.g.
18, 22, and 42) meet and interact. When layers made from different
polymeric materials (e.g. 18, 22, and/or 42) are laminated
together, the blending of the respective polymeric materials at the
junction between the layers is not considered an "interface"
because the boundary is not marked by one or more defects that may
lead to a decrease in structural integrity. In some aspects, the
liner 10, including the first capping region 66, the barrier region
70, and/or the base region 74 are joined with substantially no
interfaces between the respective layers forming a uniform bilayer
or trilayer with the appearance of a monolayer. That is, a
cross-section of the liner 10 when viewed under low magnification
will not reveal any indications of an interface or interfaces
between the first capping region 66, the barrier region 70, and/or
the base region 74. Advantageously, the lack of any appreciable
interfaces between these two or three regions 66, 70, and/or 74
significantly reduces the likelihood that these regions 66, 70,
and/or 74 will delaminate during subsequent processing (e.g.,
thermal-forming of the liner 10 into a refrigeration household
appliance 14, such as depicted in FIG. 1) and other demands of the
application environment of the liner 10. Another advantage of these
liners 10 is that the base region 74, the barrier region 70, and/or
the first capping region 66 for the liner 10 are configured with
substantially no interfaces between them, thus eliminating the
necessity of employing adhesives or other bonding agents to join
them. As these implementations of the liner 10 do not require
adhesives, they can be fabricated (e.g. through lamination
processes) at a lower cost and using faster fabrication processes.
Further, the lack of adhesives employed between these regions 66,
70, and/or 74 tends to result in improved color uniformity for
these liners 10 in comparison to conventional, pigmented
multi-layer liners with layers joined with internal adhesives. In
some aspects, the interfaces between the barrier layer 42 and the
base layer 22, the barrier layer 42 and the first polymeric capping
layer 18, and/or between the base layer 22 and the first polymeric
capping layer 18 include a polymer blend where the respective
polymeric resins used in the respective layers flow and mix to form
the corresponding polymer blends at the interface.
[0035] Referring now to FIGS. 2B and 2C, in some aspects, the liner
10 may not include the barrier layer 42 and corresponding barrier
region 70. The liner 10 without the barrier layer 42 includes the
first polymeric capping layer 18 having the first pigment additive
26 evenly dispersed throughout. The first polymeric capping layer
18 may additionally include the outer surface 62 having the
textured pattern 58 and an inner surface directly coupled or
layered onto the polymeric base layer 22. The polymeric base layer
22 may be positioned directly onto the foam layer 86 having one or
more pores 90 where the foam layer 86 is sandwiched directly
between the polymeric base layer 22 and the wrapper and/or cabinet
82. In some examples, the base layer 22 may include the second
pigment additive 34 dispersed throughout. The first pigment
additive 26 and the second pigment additive 34 may be identical in
composition and/or concentration. In examples where the first
pigment additive 26 and the second pigment additive 34 are
identical in composition, the presence of the first pigment
additive 26 in the base layer 22 may be referred to as the second
pigment additive 34 in an effort to distinguish or differentiate
the locations of the respective pigment additives. In some
examples, the base layer 22 may be provided with a lower
concentration of the second pigment additive 34 than the
concentration of the first pigment additive 26 that is provided in
the first polymeric capping layer 18. In one specific example, the
first polymeric capping layer 18 may be provided with a composition
of 70% HIPS and 30% first pigment additive 26 while the base layer
22 is provided with a composition of 70% HIPS and 30% PE mixture,
where the PE mixture has a composition of 96% PE and 4% second
pigment additive 34. However, the present disclosure is not so
limited. For example, the PE mixture may be provided with a
composition that utilizes the second pigment additive 34 at a
concentration of at least about 1%, at least about 5%, at least
about 10%, at least about 15%, at least about 20%, at least about
25%, at least about 30%, and/or combinations or ranges thereof,
with a balancing concentration of polyethylene (PE). It may be
beneficial to provide the second pigment additive 34 in the base
layer 22 at a concentration that is equal to, or generally
corresponds with (e.g., within about 10%), the concentration of the
first pigment additive 26 in the first polymeric capping layer 18.
The first capping layer thickness 94 and base layer thickness 102
may include the same thickness values described herein. Advantages
of not using the barrier layer 42 in the liner 10 can include a
reduction in weight, a reduction in liner 10 thickness, and/or a
simpler and more efficient manufacturing process.
[0036] Referring to FIG. 2D, the liner 10 is depicted with the
second polymeric capping layer 46 and corresponding second capping
region 104. The second polymeric capping layer 46 can be configured
to have a thickness 106 (e.g., through extrusion, rolling, etc.) of
about 0.10 mm to about 1.5 mm. In some aspects, the thickness 106
of the second polymeric capping layer 46 may range from about 0.25
mm to about 0.75 mm. Note that the thickness 106 of the second
polymeric capping layer 46 is given in approximate dimensions, as
would be typically associated with the second polymeric capping
layer 46 being in a sheet or layer form before incorporation into
the liner 10. The second polymeric capping layer 46 is coupled to
the first polymeric capping layer 18 such that the first polymeric
capping layer 18 is positioned between the polymeric base layer 22
and the second polymeric capping layer 46. The second polymeric
capping layer 46 may include a high-impact polystyrene (HIPS),
poly(methyl methacrylate) (PMMA), polystyrene (PS), acrylonitrile
butadiene styrene (ABS), polyurethane (PU), polypropylene (PP),
polyethylene (PE), or combinations thereof. In various examples,
the second polymeric capping layer 46 is utilized as a
scratch-resistant layer of the liner 10. In examples that employ
the second polymeric capping layer 46, the textured pattern 58 may
be formed on an outer surface 142 of the second polymeric capping
layer 46.
[0037] Referring again to FIG. 2D, the polymeric base layer 22 of
the liner 10 may include one or more pigment additives (e.g.,
second pigment additive 34), configured to impart color, tinting,
or the like into the liner 10. As understood by those with ordinary
skill in the field of the disclosure, various metallic, ceramic,
and/or polymeric, pigments and/or colorants can be added at various
concentrations within the polymeric base resin 54 in the process of
making the polymeric base layer 22 of the liner 10. In some
aspects, the second pigment additive 34 is a granulated pigment.
For example, titanium oxide can be included as the second pigment
additive 34 to achieve a white color. In other aspects, a
charcoal-sparkle appearance can be imparted to the liner 10 by
employing carbon black in one or more of quartz, mica, and
stainless steel as the second pigment additive 34. In some aspects
of the disclosure, the second pigment additive 34 is incorporated
into the base region 74 of the liner 10 at a concentration level
and disbursed to ensure that the liner 10 exhibits a particular
color, hue, or the like, as desired by the user of the household
appliance 14. In various aspects, the first pigment additive 26 may
be incorporated into the first capping region 66 and the second
pigment 34 may be incorporated into the base region 74 at
concentrations sufficient for the liner 10 to obtain the desired
color, hue, or tinting. In such aspects, the second pigment
additive 34 may aid in retention of the desired color, hue, or
tinting in the event of scratching, marring, or other aesthetic
blemishes that may occur to the liner 10. Additionally or
alternatively, the second pigment additive 34 may aid in blending
the scratches, marring, or other aesthetic blemishes such that they
are less noticeable by a user. According to some aspects, the
second pigment additive 34 is incorporated into the base region 74
of the liner 10 at a concentration from about 1% to about 15% (by
weight of the polymeric base layer 22). Optionally, the second
pigment additive 34 may be incorporated into the base region 74 at
a concentration from about 1% to about 10% (by weight of the
polymeric base layer 22). In still other aspects, the concentration
of the second pigment additive 34 in the polymeric base layer 22
may be from about 1% to about 5% (by weight of the base layer
22).
[0038] Referring further to FIG. 2D, in various examples, the one
or more polymers 30 of the polymeric base layer 22 may include a
high-impact polystyrene (HIPS), poly(methyl methacrylate) (PMMA),
polystyrene (PS), acrylonitrile butadiene styrene (ABS),
polyurethane (PU), polypropylene (PP), polyethylene (PE), or
combinations thereof. For example, the one or more polymers 30 can
include a colored polyethylene blend and a high-impact polystyrene.
In such an example, the colored polyethylene blend may be present
in the one or more polymers 30 at a concentration of about 1% by
weight, about 5% by weight, about 10% by weight, about 15% by
weight, about 20% by weight, about 25% by weight, about 30% by
weight, about 35% by weight, about 40% by weight, about 45% by
weight, about 50% by weight, and/or combinations or ranges thereof,
with the high-impact polystyrene being provided at a balancing
concentration (i.e., the two concentrations adding up to 100%) by
weight of the one or more polymers 30. In one specific example, the
colored polyethylene blend of the one or more polymers 30 includes
the second pigment additive 34 at a concentration of about 4% by
weight of the colored polyethylene blend with the balance of the
colored polyethylene blend being made up of polyethylene (i.e., 96%
polyethylene by weight of the colored polyethylene blend).
[0039] Referring still further to FIG. 2D, the concentration of the
second pigment additive 34 within the one or more polymers 30 and
the natural fiber 38 may be approximately equal, substantially
equal, or equal. In some examples, the second pigment additive 34
may be added to the one or more polymers 30 and the natural fiber
38 separately, prior to mixing the one or more polymers 30 with the
natural fiber 38. For example, the natural fiber 38 may be bleached
and pre-colored with the second pigment additive 34 prior to mixing
the natural fiber 38 with the one or more polymers 30. In such an
example, the pre-coloring of the natural fiber 38 with the second
pigment additive 34 may be carried out such that the second pigment
additive 34 is present at about the same concentration in the
natural fiber 38 as the concentration of the second pigment
additive 34 within the one or more polymers 30. Accordingly,
dilution effects of the second pigment additive 34 may be mitigated
or eliminated such that the desired color, hue, or tinting of the
liner 10 is maintained or substantially maintained. In various
examples, the natural fiber 38 may be short-length fibers (e.g., 24
mm to 30.9 mm in length), long-length fiber (e.g., 31 mm or greater
in length), or extra-long fibers (e.g., 33.4 mm or greater in
length). While a given fiber may fall into a single category of
short-length, long-length, or extra-long length, one of skill in
the art will recognize that the natural fibers 38 within the
polymeric base layer 22 may include fibers from one or more of the
fiber length categories. The natural fibers 38 may be provided with
a longitudinal spiral twist. The longitudinal spiral twist may
provide a degree of elasticity to the natural fibers 38. For
example, the degree of elasticity may be about 10% such that the
natural fibers 38 may be extended from their relaxed length to an
extended length that is about 10% greater than their relaxed length
(e.g., by application of an external force). In various examples,
the natural fibers 38 may be a cellulose-like fiber, a wood fiber,
wood pulp, cotton-lint fiber, and/or combinations thereof.
[0040] Referring now to FIGS. 3A and 3B, the method 200 of making
the liner 10 for the household appliance 14 is depicted in
schematic form. The method 200 includes mixing step 204 for mixing
the first polymeric capping layer precursor 50 and the first
pigment additive 26 to form the first polymeric capping layer 18.
In some aspects, the mixing step 204 includes mixing the first
polymeric capping layer precursor 50 with about 5% to about 30%
first pigment additive 26 by weight or from about 15% to about 25%
first pigment additive 26 by weight of the first polymeric capping
layer 18. The mixing step 204, for example, can be conducted within
an extruder or in a separate vessel or container. According to some
aspects, the mixing step 204 is conducted such that the first
polymeric capping layer precursor 50 and the first pigment additive
26 are mixed in particulate form. In some aspects, the mixing step
204 is conducted such that the first polymeric capping layer 18
exhibits a predetermined color. In some aspects, the first
polymeric capping layer 18 includes the first polymeric capping
layer precursor 50 from about 50% to about 98% by weight, from
about 60% to about 95% by weight, from about 70% to about 95% by
weight, or from about 75% to about 95% by weight of the first
polymeric capping layer 18.
[0041] Referring again to FIGS. 3A and 3B, the method 200 of making
the liner 10 for the household appliance 14 further includes
extruding step 208 for forming the polymeric base layer 22. In some
aspects, the extruding step 208 is conducted in an extruder
suitable for extrusion of thermoplastic materials into polymeric
layers. According to some aspects, the base layer formation
temperature is set between about 120.degree. F. to about
425.degree. F., about 120.degree. F. to about 160.degree. F., from
about 275.degree. F. to about 400.degree. F., or from about
290.degree. F. to about 370.degree. F. In other aspects, the
extruding step 208 is conducted with other apparatuses to
accomplish the same or similar function as would be understood by
those with ordinary skill in the art, e.g., hot-pressing apparatus,
injection molding apparatus, etc.
[0042] Still referring to FIGS. 3A and 3B, the method 200 of making
the liner 10 of the household appliance 14 further includes
laminating step 212 for laminating the first polymeric capping
layer 18 and the polymeric base layer 22 to form the liner 10 at
about the base layer formation temperature. In various examples,
the barrier layer 42 may be laminated between the first polymeric
capping layer 18 and the polymeric base layer 22 at the laminating
step 212 to form the liner 10 at about the base layer formation
temperature. In some examples, the second polymeric capping layer
46 may be laminated to the first polymeric capping layer 18 at the
laminating step 212 to form the liner at about the base layer
formation temperature. It is contemplated that any two or more of
the layers discussed herein (e.g., the first polymeric capping
layer 18, the polymeric base layer 22, the barrier layer 42, and/or
the second polymeric capping layer 46) may be laminated to one
another at the laminating step 212. According to some aspects of
the disclosure, the laminating step 212 of the method 200 is
conducted by using rollers, e.g. one or more calendaring rollers
118 (see FIGS. 4A and 4B). Accordingly, the laminating step 212
using rollers can involve rolling the first polymeric capping layer
18, the polymeric base layer 22, the barrier layer 42, and/or the
second polymeric capping layer 46 together, at about the base layer
formation temperature to form the liner 10. Depending upon the
particular arrangement or number of layers of the liner 10, the
laminating step 212 may be carried out in a plurality of sub-steps
to build the liner 10. By rolling the layers together at about the
same temperature in which they were extruded or otherwise processed
in earlier steps, the laminating step 212 ensures that the layers
are joined together with substantially no interfaces between them.
In some aspects, the liner 10 can be characterized as a bilayer, a
trilayer, or a quadlayer appearing as a monolayer having
substantially no interfaces between the two, three, or four
respective regions 66, 70, and/or 74. In some aspects, the
lamination step 212 is conducted to form the liner 10 having
substantially no interfaces between the first capping region 66,
the barrier region 70, the base region 74, and/or the second
capping region 104. In some aspects, the laminating step 212 is
conducted such that the first polymeric capping layer 18 exhibits a
predetermined color.
[0043] In some aspects, the lamination step 212 can be heated to
about the base layer formation temperature, e.g., about 275.degree.
F. to about 400.degree. F. That is, a temperature that is about the
base layer formation temperature allows for efficient laminating of
the respective layers 18, 22, 42, and/or 46. In some aspects,
temperatures considered "about the base layer formation
temperature" include temperatures less than or equal to 3.degree.
F., less than or equal to 5.degree. F., less than or equal to
10.degree. F., or less than or equal to 15.degree. F. of the
melting temperature of the polymeric base resin 54 or blend used.
The pressure applied by the rollers 118 in the lamination step 212,
and the fact that the rollers 118 are set to approximately the base
layer formation temperature, ensures that the first polymeric
capping layer 18, the base layer 22, the barrier layer 42, and/or
the second polymeric capping layer 46 are merged together during
the lamination step 212 to form the uniform liner 10.
[0044] Referring again to FIGS. 3A and 3B, the method 200 of making
the liner 10 can include step 216 of forming the textured pattern
58 on the outer surface 62 of the first polymeric capping layer 18
or the outer surface 62 of the second polymeric capping layer 46.
The method 200 of making the liner 10 can be conducted with a
shaping step (step 220) after formation of the liner in steps 204,
208, 212, and optional step 216. In various examples, step 220 may
include sub-steps 220a and 220b, as depicted in FIG. 5. As depicted
in FIG. 5, the step 220 of method 200 can be conducted by shaping
the liner 10 into a final liner 78 suitable for subsequent assembly
into the household appliance 14 by using a shaping temperature. To
impart a desired shape to the liner 10, the liner 10 may be heat
pressed or compression molded between a heated top mold 126 and a
heated bottom mold 130 (step 220a). The final liner 78 is formed to
a desired shape/design and is configured for assembly into the
household appliance 14 (e.g., the refrigeration household appliance
14 as shown in FIG. 1). In some aspects, the shaping step 220 is
conducted according to a thermal-forming process, typically at a
temperature that approaches, but does not exceed, the base layer
formation temperature, employed in earlier steps of the method 200.
In some aspects, the shaping temperature of the shaping step 220
may range between temperatures from about 200.degree. F. to about
350.degree. F.
[0045] Referring now to FIGS. 4A and 4B, in some aspects, the
method 200 of making the liner 10 of the household appliance 14 may
reduce energy usage and timing needs by directly extruding the
polymeric base resin 54 and corresponding polymeric base layer 22
into a laminating assembly 108. In these aspects, as the polymeric
base layer 22 is freshly formed using an extruder 110 where the
polymeric base layer 22 is still hot from the extrusion and forming
processes, the polymeric base layer 22 is directly positioned into
the laminating assembly 108 contemporaneously with the first
polymeric capping layer 18 while the barrier layer 42 and/or the
second polymeric capping layer 46 may be loaded from a pulley
roller 114 to be laminated into the liner 10 using one or more
rollers 118. At least one of the advantages of laminating the
freshly formed and still hot polymeric base layer 22 with the first
polymeric capping layer 18 and barrier layer 42 is the ability to
save energy from not having to heat each of the respective layers
18, 22, 42, and/or 46 to about the base layer formation
temperature. Since the temperature of the polymeric base layer 22
is about the base layer formation temperature upon being formed,
the polymeric base layer 22 may be readily laminated to the first
polymeric capping layer 18, the barrier layer 42, and/or the second
polymeric capping layer 46 to form the liner 10 with substantially
no interfaces between the respective layers (see FIGS. 2A-2D). In
some aspects, no barrier layer 42 may be incorporated and the
polymeric base layer 22 may be readily and directly laminated to
the first polymeric capping layer 18 to form the liner 10 with
substantially no interfaces between the respective layers (see
FIGS. 2B-2D). In some aspects, the second polymeric capping layer
46 may be readily and directly laminated to the first polymeric
capping layer 18 before, during, or after lamination of the first
polymeric capping layer 18 to the polymeric base layer 22. In some
aspects, the base layer formation temperature may be from about
120.degree. F. to about 160.degree. F., from about 125.degree. F.
to about 350.degree. F., from about 175.degree. F. to about
325.degree. F., or from about 200.degree. F. to about 275.degree.
F. In some aspects, the base layer formation temperature is above
the glass transition temperature for amorphous polymers or when the
amorphous polymer begins to flow and/or above the melting point for
crystalline polymers or when the crystalline polymer begins to
flow.
[0046] Still referring to FIGS. 4A and 4B, the method 200 of making
the liner 10 includes forming the textured pattern 58 on the outer
surface 62 on the first polymeric capping layer 18 (step 216). In
some aspects, the textured pattern 58 may be formed into the outer
surface 62 on the first polymeric capping layer 18 or on the outer
surface 142 of the second polymeric capping layer 46 using a
granular pattern mold roller 122. Depending on the desired
aesthetic and color appearance desired for the liner 10, the
granular pattern mold roller 122 can be configured to impart or
mold, for example, pyramidal, diamond, circular, trapezoidal,
square, tetragonal, hexagonal, polygonal, or a combination of
shapes thereof into the outer surface 62 of the first polymeric
capping layer 18. In some aspects, the textured pattern 58 may
include a 2D surface pattern, a 3D surface pattern, or a
combination thereof. The added textured or granular pattern 58
helps maintain color, prevent visible markings, and/or prevent
visible wear of the outer surface 62 of the liner 10 by offering an
alternative to a glossy or smooth finished surface that readily can
show marks or wear from the manufacturing process or normal
wear.
[0047] Referring further to FIGS. 4A and 4B, in some aspects of the
present disclosure, the liner 10 is provided with the first
polymeric capping layer 18 and the base layer 22 while the barrier
layer 42 is excluded. The polymeric base resin 54 used to form the
polymeric base layer 22 may include a high-impact polystyrene
(HIPS) precursor material, such as 1170 HIPS, the second pigment
additive 34, a polyethylene (PE), and/or the natural fiber 38. For
example, the base layer 22 may include a mixture of high-impact
polystyrene (HIPS) and colored polyethylene (PE) blend that is
present at a concentration of between about 1% to less than 50% by
weight of the polymeric base layer 22. In some examples, the
colored polyethylene blend is present at a concentration of between
about 1% and about 30% by weight of the mixture of HIPS and colored
PE blend, while the high-impact polystyrene is present at a
concentration of between about 70% and about 99% by weight of the
mixture of HIPS and colored PE blend. The colored PE blend can
include the second pigment additive 34 at a concentration of
between about 1% and about 25% by weight of the colored PE blend.
In one specific example, the colored PE blend can include 96% by
weight polyethylene and 4% by weight second pigment additive 34. In
such an example, the colored PE blend (96/4 PE/pigment) is mixed
with the HIPS material at a desired ratio to formulate the mixture
of HIPS and colored PE blend (e.g., 30% colored PE blend and 70%
HIPS). The natural fiber 38 and the mixture of HIPS and colored PE
blend can be combined to formulate the polymeric base resin 54. In
one specific example, the natural fiber 38 may be present at a
concentration of about 55% by weight of the polymeric base layer 22
and the mixture of HIPS and colored PE blend may be present at a
concentration of about 45% by weight of the polymer base layer 22.
In various examples, the colored polyethylene (PE) blend may
include a loading concentration of high-impact polystyrene (HIPS)
and the second pigment additive 34. For example, the polyethylene
(PE) mixture may include a loading concentration of high-impact
polystyrene (HIPS) of at least about 2% HIPS, at least about 4%
HIPS at least about 6% HIPS, at least about 8% HIPS, at least about
10% HIPS, at least about 12% HIPS, at least about 14% HIPS, at
least about 16% HIPS, at least about 18% HIPS, at least about 20%
HIPS, and/or combinations or ranges thereof. The first polymeric
capping layer 18 may have a composition similar to those described
herein, such as high-impact polystyrene (HIPS) with a loading
concentration of the first pigment additive 26 (see FIG. 2B). For
example, the first polymeric capping layer 18 may be made with a
composition that includes high-impact polystyrene (HIPS) at a
concentration in the range of at least about 70% to less than about
99% and a loading of the first pigment additive 26 of at least
about 1% to less than about 30%.
[0048] Referring still further to FIGS. 4A and 4B, in some aspects
of the present disclosure, the first polymeric capping layer 18 and
the base layer 22 may each be provided with a pigment additive
(e.g., the first pigment additive 26 or the second pigment additive
34) (see FIGS. 2C and 2D). As discussed above, the second pigment
additive 34 may be identical in composition to the first pigment
additive 26 in various examples. In such an example, the base layer
22 may be provided with a lower concentration of the first pigment
additive 26 than the concentration that is provided in the first
polymeric capping layer 18. In one specific example, the first
polymeric capping layer 18 may be provided with a composition of
70% HIPS and 30% first pigment additive 26 while the base layer 22
is provided with a composition of 55% natural fiber 38 and 45% of a
mixture of HIPS and colored PE blend. In this specific example, the
HIPS and colored PE blend includes 70% HIPS and 30% colored PE
blend, where the colored PE blend has a composition of 96% PE and
4% first pigment additive 26. However, the present disclosure is
not so limited. For example, the PE mixture may be provided with a
composition that utilizes the first pigment additive 26 at a
concentration of at least about 1%, at least about 5%, at least
about 10%, at least about 15%, at least about 20%, at least about
25%, at least about 30%, and/or combinations or ranges thereof,
with a balancing concentration of polyethylene (PE). It may be
beneficial to provide the first pigment additive 26 in the base
layer 22 at a concentration that is equal to, or generally
corresponds with (e.g., within about 10%), the concentration of the
first pigment additive 26 in the first polymeric capping layer 18.
The first polymeric capping layer 18 may be provided with any of
the compositions disclosed herein, including combinations thereof,
without departing from the concepts disclosed herein. Additionally,
the base layer 22 may be provided with any one of the compositions
disclosed herein or combinations thereof. Further, the base layer
22 may be provided with a composition that is a hybrid of the
compositions disclosed herein for the first polymeric capping layer
18, the base layer 22, and/or the barrier layer 42. By providing
the base layer 22 with the first pigment additive 26, in the event
of defects or deformations to the liner 10, the defects or
deformations may be at least partially blended with the surrounding
area such that the defect or deformation remains hidden or barely
perceptible to the user.
[0049] One function of the barrier layer 42, is to protect the
first polymeric capping layer 18 from defects and deformations that
result from the foam layer 86 attacking or degrading the base layer
22. The foam layer 86, in some instances, can penetrate through the
base layer 22 and interact directly with the barrier layer 42. In
the bilayer examples disclosed herein, the barrier layer 42 is
omitted. Similarly, in some of the trilayer examples disclosed
herein, the barrier layer 42 is omitted. Accordingly, the foam
layer 86 may pose a greater threat to the integrity of the first
polymeric capping layer 18 if the foam layer 86 is allowed to
interact with the first polymeric capping layer 18. Therefore, the
formulation of the base layer 22 in its various aspects and
examples has been designed as a hybrid composition that may be
provided with characteristics of both the base layer 22 and the
barrier layer 42 while remaining a uniform composition. By
adjusting the composition of the base layer 22, the foam layer 86
is not permitted to reduce the thickness of the liner 10. Instead,
the base layer 22 immediately resists degradation of the liner 10
by the foam layer 86. An additional advantage of the liners 10 that
omit the barrier layer 42 is that the first polymeric capping layer
18 and the base layer 22 are more suitable for regrinding of scrap
material such that manufacturing costs are reduced. In addition to
significant manufacturing cost savings by opening the possibility
for regrinding of scrap material, it may be beneficial to laminate
fewer layers from a manufacturing costs and complexity standpoint.
By laminating fewer layers together, fewer opportunities exist for
defects, deformations, and imperfections in the liner 10. For
example, laminating a third layer onto a bilayer can result in
deformations in not only the junction between the third layer and
the bilayer, but also can result in a disruption in the junction
between first and second layers that have already been laminated
into the bilayer. The use of fewer layers and the hybrid
composition for the base layer 22 are able to decrease cost and
waste while maintaining or improving a lifecycle of the liner 10,
which ultimately can decrease costs associated with recalls and/or
warranty repairs. The hybrid composition of the base layer 22
prevents deformation, defects, and general depolymerization or
dissolving of the base layer 22 that can result from insulating
foams that are often utilized in the household appliance 14.
Accordingly, the hybrid composition of the base layer 22 can reduce
or eliminate the drawbacks of utilizing a separate barrier layer 42
while maintaining the benefits provided by the barrier layer
42.
[0050] Liner 10 structures that employ the barrier layer 42 may be
provided with compositions that include a mixture of polyethylene
(PE) and polyethylene terephthalate (PET). For example, the barrier
layer 42 may be provided with a composition of 90% PE (e.g., 1170
HIPS) and 10% PET. While the incorporation of the barrier layer 42
helps to protect against wrinkling and other deformations, the
barrier layer 42 can introduce difficulties with manufacturing,
costs, and performance of the liner 10. For example, the barrier
layer 42 is often blended and produced as a separate layer for the
structures that employ the barrier layer 42, which increases costs,
and the barrier layer 42 is often difficult or impossible to
regrind when issues arise. When polyethylene terephthalate (PET) is
present in the barrier layer 42, and the scrap barrier layer 42 is
mixed with the first polymeric capping layer 18 and/or the base
layer 22 for remanufacturing, then serious issues arise with
thermoforming and color matching of the liner 10.
[0051] Referring to FIG. 5, the final liner 78 may be assembled
with a wrapper 134 (e.g. the cabinet 82 as shown in FIG. 1) and a
trim breaker 138 to form an insulation structure (step 220b). The
insulation structure may then be filled with the foam layer 86 or
other insulative material known in the art to form the fully
insulated cabinet 82 structure.
[0052] The method 200 of making liners 10 and their corresponding
bilayer, trilayer, or quadlayer structures result in liners 10
having better surface properties to prevent scratching or other
visible aberrations of the color and/or texture. For example, the
barrier layer 42 in combination with the textured pattern 58
positioned on the outer surface 62 or outer surface 142 of the
liner 10 hides visible scratches or markings on the liner 10. The
ability to position the first pigment additive 26 and the first
polymeric capping layer 18 on one side of the liner 10 with the
textured pattern 58 positioned on the outer surface 62 or the outer
surface 142 of the liner 10 prevents the imparted color, tinting,
hue or the like from visibly showing damage during the
manufacturing or end use of the household appliance 14.
[0053] It is understood that the descriptions outlining and
teaching the method of making the liner 10 previously discussed,
which can be used in any combination, apply equally well to the
liner 10 for the household appliance 14. Accordingly, the liner 10
includes a polymeric liner having the bilayer, trilayer, or
quadlayer structure where the bilayer, trilayer, or quadlayer
structure includes: the first polymeric capping layer 18 including
a high-impact polystyrene material and the first pigment additive
26 wherein the outer surface 62 of the first polymeric capping
layer 18 may include the textured pattern 58; the polymeric base
layer 22 including a high-impact polystyrene material, the natural
fiber 38, and optionally the second pigment additive 34; in some
examples, the barrier layer 42 including a polyethylene material
wherein the barrier region 70 is disposed between the first
polymeric capping layer 18 and the polymeric base layer 22; and in
various examples, the second polymeric capping layer 46 including a
poly(methyl methacrylate) material wherein the second polymeric
capping layer 46 is disposed upon the first polymeric capping layer
18 such that the first polymeric capping layer 18 is positioned
between the polymeric base layer 22 and the second polymeric
capping layer 46. The first polymeric capping layer 18, the
polymeric base layer 22, the barrier layer 42, and/or the second
polymeric capping layer 46 are directly coupled with substantially
no interfaces between them in the structure. The first polymeric
capping layer 18 and the polymeric base layer 22 are directly
coupled with substantially no interfaces between them in the
bilayer structure.
[0054] According to another aspect of the present disclosure, a
household appliance liner includes a first polymeric capping layer
and a polymeric base layer. The first polymeric capping layer
includes a first pigment additive. The polymeric base layer is
coupled to the first polymeric capping layer. The polymeric base
layer includes one or more polymers, a second pigment additive, and
a natural fiber. The natural fiber is present at a concentration of
at least 50% by weight of the polymeric base layer.
[0055] According to another aspect of the present disclosure, a
household appliance liner includes a second polymeric capping layer
coupled to a first polymeric capping layer such that the first
polymeric capping layer is positioned between a polymeric base
layer and the second polymeric capping layer.
[0056] According to another aspect of the present disclosure, a
household appliance liner includes a second polymeric capping layer
that is a scratch-resistant layer.
[0057] According to another aspect of the present disclosure, a
household appliance liner includes a second polymeric capping layer
that includes poly(methyl methacrylate).
[0058] According to another aspect of the present disclosure, a
household appliance liner includes a first pigment additive in a
first polymeric capping layer, where the first pigment additive is
present at a concentration of about 5% to about 30% by weight of
the first polymeric capping layer.
[0059] According to another aspect of the present disclosure, a
household appliance liner includes a first polymeric capping layer
that includes a first polymeric capping layer precursor at a
concentration of about 70% to about 95% by weight of the first
polymeric capping layer.
[0060] According to another aspect of the present disclosure, a
household appliance liner includes a second pigment additive that
is present in a polymeric base layer at a concentration of about 1%
to about 30% by weight of the polymeric base layer.
[0061] According to another aspect of the present disclosure a
household appliance liner includes a polymeric base layer that
includes one or more polymers, where the one or more polymers
include a colored polyethylene blend and a high-impact
polystyrene.
[0062] According to another aspect of the present disclosure, a
household appliance liner includes a colored polyethylene blend
with a second pigment additive, where the second pigment additive
is present at a concentration of about 4% by weight of the colored
polyethylene blend, and wherein the colored polyethylene blend
includes polyethylene at a concentration of about 96% by weight of
the colored polyethylene blend.
[0063] According to another aspect of the present disclosure, a
household appliance liner includes one or more polymers, where the
one or more polymers include a colored polyethylene blend that is
present at a concentration of about 30% by weight of one or more
polymers and a high-impact polystyrene that is present at a
concentration of about 70% by weight of the one or more
polymers.
[0064] According to another aspect of the present disclosure, a
household appliance liner includes a polymeric base layer that
includes one or more polymers and a natural fiber, where the
polymeric base layer includes a concentration of a second pigment
additive that is about equal within the one or more polymers and
the natural fiber.
[0065] According to another aspect of the present disclosure, a
household appliance liner includes a natural fiber that is bleached
and pre-colored with a second pigment additive prior to mixing the
natural fiber with one or more polymers.
[0066] According to another aspect of the present disclosure, a
household appliance liner includes a second pigment additive that
is added to one or more polymers and a natural fiber in equal
amounts prior to mixing the one or more polymers and the natural
fiber.
[0067] According to another aspect of the present disclosure, a
household appliance liner includes a barrier layer that is coupled
to a polymeric base layer such that the barrier layer is positioned
between a first polymeric capping layer and the polymeric base
layer.
[0068] According to another aspect of the present disclosure, a
household appliance liner includes a first polymeric capping layer
and a polymeric base layer. The first polymeric capping layer
includes a first pigment additive and a first polymeric capping
layer precursor. The first pigment additive is present at a
concentration of about 5% to about 30% by weight of the first
polymeric capping layer. The first polymeric capping layer
precursor is present at a concentration of about 70% to about 95%
by weight of the first polymeric capping layer. The polymeric base
layer is coupled to the first polymeric capping layer. The
polymeric base layer includes one or more polymers, a second
pigment additive, and a natural fiber. The second pigment additive
is present in the polymeric base layer at a concentration of about
1% to about 30% by weight of the polymeric base layer. The natural
fiber is present at a concentration of at least 50% by weight of
the polymeric base layer.
[0069] According to another aspect of the present disclosure, a
household appliance liner includes one or more polymers present
within a polymeric base layer. The one or more polymers include a
colored polyethylene blend and a high-impact polystyrene. The
colored polyethylene blend includes a second pigment additive at a
concentration of about 4% by weight of the colored polyethylene
blend. The colored polyethylene blend includes polyethylene at a
concentration of about 96% by weight of the colored polyethylene
blend.
[0070] According to another aspect of the present disclosure, a
household appliance liner includes one or more polymers. The one or
more polymers include a colored polyethylene blend is present at a
concentration of about 30% by weight of the one or more polymers
and the high-impact polystyrene that is present at a concentration
of about 70% by weight of the one or more polymers.
[0071] According to another aspect of the present disclosure, a
method of making a liner for a household appliance is disclosed.
The method includes mixing a first polymeric capping layer
precursor and a first pigment additive to form a first polymeric
capping layer, where the first pigment additive is present at a
concentration of about 5% to about 30% by weight of the first
polymeric capping layer; mixing one or more polymers, a second
pigment additive, and a natural fiber to form a polymeric base
resin; extruding the polymeric base resin to form a polymeric base
layer at a base layer formation temperature, where the second
pigment additive is present in the polymeric base layer at a
concentration of about 1% to about 30% by weight of the polymeric
base layer, and where the natural fiber is present at a
concentration of at least 50% by weight of the polymeric base
layer; and laminating the polymeric base layer and the first
polymeric capping layer to form the liner at about the base layer
formation temperature.
[0072] According to another aspect of the present disclosure a
method of making a liner for a household appliance includes mixing
a second pigment additive with one or more polymers and a natural
fiber in equal amounts prior to mixing the one or more polymers and
the natural fiber together.
[0073] According to another aspect of the present disclosure, a
method of making a liner for a household appliance includes
bleaching a natural fiber and pre-coloring the natural fiber with a
second pigment additive. The bleaching and pre-coloring of the
natural fiber may occur prior to mixing the natural fiber with one
or more polymers.
[0074] It will be understood by one having ordinary skill in the
art that construction of the described device and other components
is not limited to any specific material. Other exemplary
embodiments of the device disclosed herein may be formed from a
wide variety of materials, unless described otherwise herein.
[0075] For purposes of this disclosure, the term "coupled" (in all
of its forms, couple, coupling, coupled, etc.) generally means the
joining of two components (electrical or mechanical) directly or
indirectly to one another. Such joining may be stationary in nature
or movable in nature. Such joining may be achieved with the two
components (electrical or mechanical) and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two components. Such joining may
be permanent in nature or may be removable or releasable in nature
unless otherwise stated.
[0076] It is also important to note that the construction and
arrangement of the elements of the device as shown in the exemplary
embodiments is illustrative only. Although only a few embodiments
of the present innovations have been described in detail in this
disclosure, those skilled in the art who review this disclosure
will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.) without
materially departing from the novel teachings and advantages of the
subject matter recited. For example, elements shown as integrally
formed may be constructed of multiple parts or elements shown as
multiple parts may be integrally formed, the operation of the
interfaces may be reversed or otherwise varied, the length or width
of the structures and/or members or connector or other elements of
the system may be varied, the nature or number of adjustment
positions provided between the elements may be varied. It should be
noted that the elements and/or assemblies of the system may be
constructed from any of a wide variety of materials that provide
sufficient strength or durability, in any of a wide variety of
colors, textures, and combinations. Accordingly, all such
modifications are intended to be included within the scope of the
present innovations. Other substitutions, modifications, changes,
and omissions may be made in the design, operating conditions, and
arrangement of the desired and other exemplary embodiments without
departing from the spirit of the present innovations.
[0077] It will be understood that any described processes or steps
within described processes may be combined with other disclosed
processes or steps to form structures within the scope of the
present device. The exemplary structures and processes disclosed
herein are for illustrative purposes and are not to be construed as
limiting.
[0078] It is also to be understood that variations and
modifications can be made on the aforementioned structures and
methods without departing from the concepts of the present device,
and further it is to be understood that such concepts are intended
to be covered by the following claims unless these claims by their
language expressly state otherwise.
[0079] The above description is considered that of the illustrated
embodiments only. Modifications of the device will occur to those
skilled in the art and to those who make or use the device.
Therefore, it is understood that the embodiments shown in the
drawings and described above are merely for illustrative purposes
and not intended to limit the scope of the device, which is defined
by the following claims as interpreted according to the principles
of patent law, including the Doctrine of Equivalents.
* * * * *